Electrical wire dispensing device and package

ABSTRACT

A disposable or recyclable device that can be used by a manufacturer as a shipping container for coils of wire or cable and subsequently by a contractor to support and unwind electrical wire in a manner that prevents the undesired kinking or knotting of such wire is disclosed. The circular base of the device has outer and inner raised walls where the base is suspended by equally spaced support lines of equal length, with one end of each line being attached to the inner raised wall of the base and its opposite end being attached to a swivel hook assembly. For shipping and distribution by the manufacturer, the electrical wire is placed within the walls of the circular base and the support lines with swivel hook assembly are folded within the center compartment formed by the inner raised wall. For use the support lines are extended upward from the center compartment of the support base and the device is attached to an overhead beam or pipe by means of the swivel hook assembly. The free end of the electrical wire is pulled over the outer wall of the support to the desired length and frictionally engages that wall in order to preclude uncoiling of the wire in excess of a desired amount.

FIELD OF THE INVENTION

The present invention is directed to a device for shipping/distributingcoiled wire and cable as well as dispensing coiled wire and cable. It isspecifically directed to a disposable or recyclable self-containeddevice that wire manufacturers can use as a shipping and distributioncontainer for coiled wire and cable products as well as a device thatcontractors can use for dispensing wire or cable which precludes kinkingof the wire or cable as it is dispensed.

BACKGROUND OF THE INVENTION

Electrical wire commonly used in the residential and commercialconstruction industry is generally manufactured in coils ofpredetermined lengths and diameters. The individual coils of wire aretypically shipped and sold to contractors in boxes or as a roll inplastic-wrap material. In order to use the electrical wire, thecontractor must pull the wire from its shipping box or uncoil the wirefrom its roll configuration once the plastic-wrap is removed. Eventhough the box which the coil of electrical wire is shipped in willoften contain access holes, when the electrical wire is pulled from itsbox it will often become kinked or knotted which in turn requires thecontractor to temporarily discontinue installation of the wire in orderto remove the kinks or knots from the electrical wire. Where themanufacturer/distributor packages the coil of electrical wire inplastic-wrap material, kinking or knotting becomes even moreproblematic.

U.S. Pat. No. 3,729,092 is directed to a portable support on whichcoiled electrical wire can be placed and then hung to permit the wire tobe pulled and unwound from the support base for use. The '092 inventiondoes not provide a means for a wire manufacturer to distribute itsproduct, nor does the '092 invention employ a means for preventing thebase from continuously rotating once the user discontinues pulling wirefrom the device, and thus dispensing wire unnecessarily.

U.S. Pat. No. 3,974,980 is directed to a wire reel for dispensing theelectrical wire from its cardboard box or its coiled form. Similar tothe invention of the '092 patent, the invention of the '980 patentutilizes a base support for the electrical wire and a means forsuspending the device when in use. The '980 invention employs aguide/leader loop through which the electrical wire is pulled as it isuncoiled from the dispensing device for installation as well as abraking system to retard unwanted rotation of the device to preventuncoiling. The '980 device is constructed of numerous parts which mayrequire adjustment or become lost, thus adding to its complexity for useand in the manufacturing of the device. Also, the '980 invention doesnot provide a simple means for a wire manufacturer to distribute itscoiled wire to contractors.

U.S. Pat. No. 4,973,011 is directed to a device that allows theunwinding of coiled wire from the cardboard box in which it is packagedfor sale and distribution. Similar to the above referenced '092 and '980patents, the '011 patent employs a base support for the coiled wire. The'011 patent is functionally similar to the devices of the '092 and '980patents in that all utilize a means to hang the devices during use.However, the '011 patent is limited to wire coils that are packaged incardboard boxes, and therefore not capable of serving as both a shippingcontainer and wire dispenser.

SUMMARY OF THE INVENTION

As has been shown by the prior art, eliminating the kinking or knottingof electrical wire during installation advantageously decreases both thetime and costs of installation. However, additional savings can berealized by the contractor if the electrical wire shipping container canalso be used to dispense the electrical wire thereby eliminating theneed to purchase additional equipment for installation.

The present invention is an easy to use device consisting of relativelyfew parts, which serves the dual purpose of a shipping container forwire manufacturers, and a wire dispensing device to be used bycontractors when installing the wire. The multi-functional aspect of asimple and portable device for shipping and dispensing wire, which isreadily disposable or recyclable, distinguishes the subject device fromthe prior art.

Thus, in accordance with the present invention the electrical wireremains within the device during use by the contractor and fortransporting the electrical wire from work site to work site. Anotherimportant aspect of the present invention is its ease of use andportability. The present invention has relatively few parts, none ofwhich need to be adjusted before or during use. Additionally, the smallsize of the device and the mechanism by which it is secured to anoverhead beam or pipe insures that the present invention will be easilyrepositioned at the work site and easily transported from work site towork site. Finally, since the device is manufactured from materials thatare both commonplace and economical, once the supply of electrical wireis completely consumed by the contractor the device may simply bediscarded or disposed of at an appropriate recycling center.

Accordingly, the present invention is directed to a wire dispensingdevice having a flat, rigid base for supporting a coil of wire, the coilhaving an inner diameter, an outer diameter, and a height, the basedefining an inner region and an outer perimeter greater than the outerdiameter of the coil, the outer perimeter defining an outer wallextending outwardly therefrom and having a height at least equal to theheight of the coil, and support lines connected to and extending fromthe inner region of the base and converging to a rotatable hangingmeans. Preferably, the wire dispensing device is circular in shape.Preferably, the inner region defines a center compartment for stowage ofthe support lines and the hanging means. Most preferably, the innerregion of the base has an inner wall extending upwardly from the base,which is, most preferably, circular and concentric with the outer wall,and which has a diameter less than the inner diameter of the coil.Preferably, an upper ridge extends inwardly from the upper surface ofthe inner wall, parallel to the base. In a preferred embodiment thesupport lines are connected to and extend from the upper ridge.Alternatively, the support lines are connected to and extend from theinner wall. While the support lines may be formed of any suitablematerial such as metal chain, in the preferred disposable/recyclableembodiment of the present invention they are formed of polymeric rope.

In another aspect the present invention is directed to a package fordistributing and dispensing a coil of wire, which has a flat, rigid basefor supporting a coil of wire, the coil having an inner diameter, anouter diameter, and a height, the base defining an outer perimetergreater than the outer diameter of the coil and an inner region, supportlines connected to and extending from the inner region of the base andconverging to a rotatable hanging means, wherein the inner region of thebase forms a center compartment for stowage of the support lines andhanging means, and an outer covering, which may be, for example, plasticsheeting material, a box or a strap.

Thus, preferably the base of the device is circular in shape with araised outer wall and a raised inner wall. The upper edge of the innerwall terminates in a flat ridge parallel to the base of the device andcreates a center compartment within the base. The base is suspended bylines of polymeric rope or metal chains of equal length. The supportlines extend upwardly and are symmetrically spaced around the flat ridgeof the inner wall, with one end of each line being attached to the flatridge of the inner wall on the base and its opposite end being attachedto a swivel hook assembly. The support lines with swivel hook assemblyare stored within the center compartment during shipping and fortransportation between work sites. For use the support chains areextended upward from the center compartment of the support base and thedevice is attached to an overhead beam or pipe by means of the swivelhook assembly. The swivel hook assembly provides the means forsuspending the device from and attaching the device to an overhead beamor pipe during use and simultaneously permits the base to freely rotateas wire is dispensed from the device. The free end of the electricalwire is pulled over the outer wall of the base to the desired length.The contact between the electrical wire and the upper edge of the outerwall prevents continued rotation of the device when the contractordiscontinues pulling electrical wire from the device. In an alternativeembodiment, the free end of the electrical wire is fed through a guideloop, which prevents over feeding of the wire.

Another alternative embodiment of the present invention eliminatescertain structures of the device, which may simplify and reducemanufacturing costs. In the alternative embodiment of the device, theinner wall and its associated flat ridge are removed, thereby creating acircular center opening having a diameter less than the inner diameterof the coiled electrical wire. The support lines of the alternativeembodiment are symmetrically spaced and attached to the perimeter of thecircular center opening. All the remaining components of the deviceremain the same and function as previously described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a coil of electrical wire on theassembled device in preparation for use;

FIG. 2 is an enlarged vertical view of the swivel hook assembly withattached support lines;

FIG. 2A is a cross-sectional view of a portion of the swivel hookassembly of FIG. 2, specifically the independently relatable extendedlip bearing a guide loop line;

FIG. 2B is a cross-sectional view of a portion of the swivel hookassembly of FIG. 2, specifically the independently ratable sleevebearing the support lines;

FIG. 2C is a cross-sectional view of a portion of the swivel hookassembly of FIG. 2, specifically the assembly pin;

FIG. 3 is a perspective view of the circular base showing the outerwall, the inner wall with its raised flat ridge for attaching supportlines, and center compartment created by the inner wall;

FIG. 4 is an enlarged vertical view of the knotted means for attaching asupport line to the support base of the device;

FIG. 4A is an enlarged vertical view of an alternative, eye-bolt meansfor attaching a support line to the support base of the device;

FIG. 5 is a vertical view showing a full coil of electrical wire with alength being dispensed and engaging the outer wall of the device;

FIG. 6 is a vertical view showing a partial coil of electrical wire witha length being dispensed and engaging the outer wall of the device;

FIG. 7 is a perspective view of an alternative embodiment of the deviceincluding a separator plate;

FIG. 8 is an enlarged vertical view of the swivel hook assembly of thedevice of FIG. 9;

FIG. 9 is a perspective view of an alternative embodiment of the deviceshowing a coil of electrical wire and support lines extending upwardfrom the inner region of the device; and

FIG. 10 is a perspective view showing an alternative embodiment of thedevice showing the attachment of the support lines to the inner regionof the device.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed to a device that serves as a packagefor a coil of electrical wire and also as a device for dispensingelectrical wire which prevents the unwanted knotting or kinking duringinstallation. In the most preferred embodiment, the present device isformed of lightweight, polymeric components which may be discarded butwhich preferably are recyclable.

As can be ascertained in FIG. 1, the device 10 is comprised ofrelatively few components. The circular base of the device as shown inFIG. 3 can be manufactured from any economical, lightweight, rigidmaterial, preferably a recyclable plastic. The circular base 2 iscomprised of an outer wall 6, a flat base 13, an inner wall 11 with anupper flat ridge 7 that is parallel to the flat base 13, and a circularcenter compartment 8 formed by the raised inner wall 11. The diametersof the outer wall 6 and the inner wall 11 either accommodate or exceedthe outside and inside diameters of the coil of electrical wire 1 (seeFIGS. 5 and 6) thereby permitting the wire manufacturer to use thedevice as a shipping/distribution container. The support lines 3, beingconstructed of a suitable stiff polymeric rope material, aresymmetrically attached 12 to the flat ridge of the inner wall by meanssuch as knotting 15, shown in FIG. 4, or eye-bolts 17 through which thelines are knotted or rings 19 are attached, shown in FIG. 4A. Theopposite ends of the support lines 3 are attached to a swivel hookassembly 5 as can be seen in FIGS. 1 and 2.

As shown in FIG. 2, the swivel hook assembly is comprised of a hook 20,and a downwardly extending assembly portion 22. Downwardly extendingassembly portion 22 includes downwardly extending shaft 24 (not visiblein FIG. 2, but indicated in cross-section in FIGS. 2A-2C). Independentlyrotatable sleeve 26, which bears the support lines 3, is carried on androtates about shaft 24. As shown in FIG. 2, rings 28 attach the supportlines to rotatable sleeve 26. However, any other suitable means,including simple knotting means, may be employed. Thus, rotatable sleevemay include spaced holes, which receive the support lines, as shown inFIG. 2B, or downwardly extending hooks or eyes to which the supportlines may be attached. Regardless of the means for attaching the linesto the rotatable sleeve, preferably they are symmetrically spaced, bothto the swivel hook assembly and to the base of the device. At leastthree, preferably at least four support lines are employed. All are ofequal length. Lowermost sleeve 30, through which extends locking pin 32,secures the lower assembly components onto shaft 24.

The embodiment of FIGS. 1 and 2 includes a guide line 40 for controllingthe amount of electrical wire dispensed. If it is employed, guide line40 is attached to the swivel hook assembly as is shown in FIG. 2.Specifically, for such embodiment the downwardly extending assemblyportion 22 of the swivel hook assembly includes independently rotatableextended lip 34 to which the guide line is attached by means such asring 36, shown in FIG. 2, or other appropriate means such as simpleknotting means. Independently rotatable extended lip 34, shown incross-section in FIG. 2A, rotates about shaft 24 in a manner similar to,but independent from, the rotation of sleeve 26. In order for the guideline 40 to be outboard of the support lines 3, extended lip 34 must beabove sleeve 26. Guide line 40 includes loop 42 at its terminal end.

During operation the electrical wire is fed through loop 42. When theuser pulls the wire, loop 42 prevents an undesirable excess ofelectrical wire from being dispensed. It should be noted that guide line40, loop 42, and extended lip 34 are optional components of the presentdevice. Generally, frictional engagement of the electrical wire as it ispulled past or over outer wall 6 provides sufficient braking action tocontrol and preclude overfeeding of the wire. See, specifically, FIGS. 5and 6.

FIG. 7 illustrates an alternative embodiment 10′ of the presentinvention, which includes alternative swivel hook assembly 50, shown inan enlarged view in FIG. 8. Swivel hook assembly 50 includes a D-ring 52rotatably connected to the base of a clasp-type hook 54. It should benoted that the hook 20 of swivel hook assembly 5 may be employed inplace of clasp-type hook 54 and a clasp-type hook may be used in placeof hook 20 in the swivel hook assembly of FIGS. 1 and 2. Support lines60 are carried by D-ring 52 by means of rings 62, shown, or by any othersuitable means. As above, at least three, preferably at least foursupport lines are employed. As shown in FIGS. 7 and 8 support lines 60are of a chain configuration. Any suitable type of line may be employedincluding metal or polymeric chain, rope, or cable. However, for thepreferred embodiment of the present invention in which the device isdisposable or recyclable, lightweight, polymeric components arepreferred. Thus, if the support lines are formed of a lightweightmaterial and a swivel hook assembly such as shown in FIGS. 7 and 8 isemployed, spacer 64 is required. Specifically, it has been found inaccordance with the present invention that lightweight support lineswill become entangled during operation of the device without someseparating means. For the swivel hook assembly shown in FIGS. 1 and 2,rotatable sleeve 26 serves to preclude entanglement of the lines. Forthe more simple swivel hook assembly of FIGS. 7 and 8, spacer 64 isrequired. Spacer 64 may include spaced holes 66 through which thesupport lines run, as shown in FIG. 7, or spaced notches which receivethe lines. As above, it is preferred that the support lines aresymmetrically spaced, both at the spacer and at the base.

FIGS. 9 and 10 illustrate yet a further embodiment 90 of the presentinvention. In this embodiment the inner wall is missing and the supportlines 91 are attached directly to the floor 93 by any suitable means.Outer wall 96 provides a braking action upon frictional engagement ofthe electrical wire as it is drawn from the device. As shown in FIG. 9neither a rotatable spacer neither sleeve nor a spacer are provided.Accordingly, this represents a less preferred embodiment in which thedevice components, specifically the support lines are formed of adurable, heavy material rather than a lightweight, disposable orrecyclable material. That is, although the present invention preferablyis directed to a lightweight, disposable or recyclable device, some ofthe features of the present invention may be employed advantageously ina more long-lived device. Such device, which would be formed of, forexample, machined metal, metal chain support lines, and a durable metalswivel hook assembly, likewise would benefit from the raised outer walldefined at the outer perimeter of the base and would, therefore, bewithin the scope of the present invention. Thus, all of the structuralfeatures of the present invention may be employed either in thepreferred disposable or recyclable embodiment or in the alternativedurable embodiment. The only caveat is that for the lightweight,disposable or recyclable embodiment, some means must be provided forprecluding entanglement of the lightweight support lines. Such is notrequired for the heavier, more durable embodiment. Thus, for example,although FIGS. 9 and 10 represent a heavyweight device, as is evidencedby the lack of a spacer or spacing sleeve on the swivel hook assembly, adisposable device may omit the inner wall as is shown in those Figures.For such embodiment the swivel hook assembly and support lines may becontained in the opening formed by the inner diameter of the coil ofelectrical wire during packaging, such as by plastic overwrap.

Thus, for shipping and distribution the present inventive device iswrapped in a protective covering, such as plastic wrap or other suitablematerial, to keep the coil of electrical wire 1 properly positionedwithin the outer wall and the inner wall, if one is employed, and tokeep the support lines and the swivel hook assembly inside the centercompartment, if one is present, or, if not, inside the inner diameter ofthe electrical wire coil. To use the device the protective covering isremoved and the support lines are pulled upward. The device is suspendedfrom an overhead beam or pipe by means of the swivel hook assembly. Asthe free end of the electrical wire 1 is pulled outward and over theouter wall of the device to the desired length, the device rotates bymeans of the swivel hook assembly. When the contractor discontinuespulling the electrical wire 1 from the device, the contact between theelectrical wire 1 and the guide line loop or, more preferably, the upperedge of the outer wall, frictionally prevents continued rotation of thedevice and the unnecessary release/uncoiling of additional electricalwire.

The foregoing description in the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, in the skill or knowledge of the relevant art arewithin the scope of the present invention. The embodiments describedherein are further intended to explain the best modes known forpracticing the invention and to enable others skilled in the art toutilize the invention in such, or other, embodiments and with variousmodifications required by the particular applications or uses of thepresent invention. It is intended that the appended claims be construedto include alternative embodiments to the extent permitted by the priorart.

1. A wire dispensing device comprising: a flat, rigid base forsupporting a coil of wire, the coil having an inner diameter, an outerdiameter, and a height, the base defining an outer perimeter greaterthan the outer diameter of the coil and an inner region the outerperimeter defining an outer wall extending upwardly therefrom and havinga height at least equal to the height of the coil; and a plurality ofsupport lines connected to and extending from the inner region of thebase and converging to a rotatable hanging means.
 2. The wire dispensingdevice as set forth in claim 1 wherein the base is circular in shape. 3.The wire dispensing device as set forth in claim 1 wherein the height ofthe outer wall is greater than the height of the coil.
 4. The wiredispensing device as set forth in claim 2 wherein the inner region ofthe base comprises a center compartment for stowage of the support linesand hanging means.
 5. The wire dispensing device as set forth in claim 1wherein the inner region of the base comprises an inner wall extendingupwardly from the base.
 6. The wire dispensing device as set forth inclaim 5 wherein the inner wall is circular and concentric with the outerwall, having a diameter less than the inner diameter of the coil.
 7. Thewire dispensing device as set forth in claim 6 further comprising anupper ridge extending inwardly from the upper surface of the inner walland parallel to the base.
 8. The wire dispensing device as set forth inclaim 7 wherein the support lines are connected to and extend from theupper ridge.
 9. The wire dispensing device as set forth in claim 5wherein the support lines are connected to and extend from the innerwall.
 10. The wire dispensing device as set forth in claim 1 wherein thesupport lines comprise metal chain.
 11. The wire dispensing device asset forth in claim 1 wherein the support lines comprise polymeric rope.12. The wire dispensing device as set forth in claim 1 wherein thesupport lines are symmetrically spaced.
 13. A disposable or recyclablepackage for distributing and dispensing a coil of wire, comprising: aflat, rigid base supporting a coil of wire, the coil having an innerdiameter, an outer diameter, and a height, the base defining an outerperimeter greater than the outer diameter of the coil and an innerregion; a plurality of support lines connected to and extending from theinner region of the base and converging to a rotatable hanging means;wherein the inner region of the base comprises a center compartment forstowage of the support lines and hanging means; and an outer covering.14. The package set forth in claim 12 wherein the outer coveringcomprises an overwrapped plastic sheeting material.
 15. The package setforth in claim 12 wherein the outer covering comprises a box.
 16. Thepackage set forth in claim 12 wherein the outer covering comprises astrap.
 17. The package set forth in claim 12 wherein the base iscircular in shape.
 18. The package set forth in claim 12 wherein theinner region of the base comprises an inner wall extending upwardly fromthe base.
 19. The package set forth in claim 12 wherein the supportlines comprise polymeric rope.
 20. The package set forth in claim 12further comprising means for symmetrically spacing the support lines.